NC Machine Tool Sensor Data Aggregation for Easier Status Evaluation
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Solution Overview
Problem
Existing data storage devices for numerically controlled machine tools generate large, confusing amounts of unfiltered sensor data, making it difficult to evaluate and display machine status independently of the machine tool or control system, and increasing data processing loads.
Innovation Solution
A data storage device with a configurable interface and processing unit that aggregates sensor data based on specified rules, allowing for flexible readout and processing of sensor signals, and transmission to external devices via universal interfaces like OPC UA or MQTT, enabling centralized storage and analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If all sensor signals are stored with the same sampling frequency in individual channels, then complete sensor data is preserved, but data volume becomes large and confusing
Solution Approach 1:
The patent segments sensor data storage by creating multiple data sets with different sampling frequencies tailored to specific sensor groups. Instead of storing all sensor data at a uniform high sampling rate, the system divides sensors into groups and assigns appropriate sampling frequencies to each group based on their specific requirements, thereby reducing overall data volume while preserving critical information.
Solution Approach 2:
The patent changes the sampling frequency parameter dynamically for different sensor groups. The control device is configured to read out sensor signals at different sampling frequencies depending on the sensor group and the operational mode of the machine tool, allowing the system to adapt data acquisition parameters to actual needs and reduce unnecessary data storage.
2Loss of information
If unfiltered sensor data is stored from all sensors, then all available information is captured, but data evaluation and display becomes difficult
Solution Approach 1:
The patent extracts and stores only the most relevant sensor data for specific evaluation purposes. By identifying and separating critical sensor signals from the general data stream, the system creates dedicated data sets that contain pre-filtered, purpose-specific information, making data evaluation more straightforward while retaining access to complete data when needed.
Solution Approach 2:
The patent creates a universal data storage structure that serves multiple evaluation purposes simultaneously. The system organizes sensor data into standardized data sets that can be used for different types of analysis and monitoring tasks, making the data more versatile and easier to evaluate across various applications without losing information.
3Measurement precision
If high sampling frequency is used for all sensors, then detailed sensor data is captured, but data processing load on controller increases
Solution Approach 1:
The patent segments the sensor monitoring system into different groups with different sampling requirements. Critical sensors that require high measurement precision are monitored at high sampling frequencies, while less critical sensors are monitored at lower frequencies, thereby distributing the processing load appropriately and reducing overall controller burden.
Solution Approach 2:
The patent dynamically changes the sampling frequency parameter based on sensor group and operational context. The control device adjusts readout frequencies adaptively, using high sampling rates only when and where measurement precision is critical, and reducing sampling rates for other sensors, thereby optimizing the balance between data quality and processing load.
4Quantity of substance
If machine-specific sensor data storage is used, then all sensor data is available, but universal access independent of machine tool type becomes difficult
Solution Approach 1:
The patent implements a universal data storage and access architecture that can handle sensor data from different machine tool types and control systems. By establishing standardized data set structures and interfaces, the system enables consistent data evaluation across various machine types while maintaining the ability to store and access complete sensor data for each specific application.
Data Source
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AI summary
The present invention relates to a data storage device 300 for use with a numerically controlled machine tool 100 that comprises a control device 200 for controlling a plurality of actuators 110 of the machine tool 100 and a plurality of sensors 120 for sending sensor signals indicating a machine state of the machine tool 100 to the control device 200. The data storage device 300 comprises a first interface unit 310; a first storage medium 360 for storing configuration data 361 that indicate a group of sensors of the machine tool as well as read-out and processing rules for sensor signals of the group of machine tool sensors; a read-out unit 320 for reading out sensor signal values of the sensor signals sent by the group of machine tool sensors specified in the configuration data via the first interface unit, on the basis of the read-out rules specified in the configuration data; a data processing unit 330 for processing the sensor signal values read out by means of the read-out unit such as to obtain aggregated sensor system data, on the basis of the processing rules specified in the configuration data; a second storage medium 370 for storing the sensor system data 381; and a second interface unit 340 for data transmission to an external data processing unit 220, 400 and/or 500.